The invention relates to a protective sports helmet purposely designed for a selected group of helmet wearers from amongst a larger population of helmet wearers. A multi-step method for helmet design starts by collecting information from a population of players that may include information about the shape of a player's head and the impacts the player has sustained. This information is then processed to create player population information that is sorted to create categories. Advanced mathematical techniques are utilized to further sort these categories into player groups or data sets based on player attributes. Once the player groups are identified, another multi-step process is utilized to design optimized helmet prototype models for each player group. These optimized helmet prototype models are then further processed into complete helmet models by determining a structural design and chemical composition that is manufacturable and has mechanical properties that are substantially similar to the optimized helmet prototype model. Physical helmet prototypes are then created and tested using a unique helmet standard derived from information associated with each player group. Once the prototypes pass testing, the complete helmet models can be manufactured to create actual stock helmets or stock helmet components for future players whose characteristics and attributes place them within the selected player group.

A pressure sensing system for measuring pressure acting between a user's head and a protective helmet includes a flexible article that is configured to fit between a wearable protective article and a body part of a user. The system further includes a pressure sensor array comprising a plurality of pressure sensors secured to the flexible article. The system may include a data acquisition module configured to provide data from the pressure sensor array to a computer having a display that provides pressure data to a user.

A system for forming a deep drawn helmet and method therefor are disclosed. The system includes a forming draw ring and a non-forming draw ring and supports a prepreg stack between a forming aperture of the forming draw ring and a non-forming aperture of the non-forming draw ring. The system clamps a flange portion of the prepreg stack between a contact surface of the forming draw ring and a contact surface of the non-forming draw ring, which forms a clamped assembly of the rings and the prepreg stack. The system then forms a deep drawn helmet preform from the prepreg stack of the clamped assembly. The same system or a different forming system then consolidates one or more of the preforms into a final deep drawn helmet. The system can control sliding of the flange during forming of the helmet preform without reducing the flange clamping force.

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

A helmet and method for forming a helmet having a multi-density impact liner may include forming a puck comprising an interface surface and at least one side is formed. The interface surface of the puck is placed in direct contact with a receiving surface of a cap located in an impact liner mold. Next, the interface surface of the puck is thermally fused directly to the receiving surface of the cap while contemporaneously an impact liner body is formed inside the mold. The impact liner body is fused to the at least one side of the puck, and to a majority of the receiving surface of the cap. The density of the puck may be greater than the density of the impact liner body. The puck and the impact liner body may be expanded polystyrene (EPS), and the cap may be polycarbonate (PC).

Disclosed are apparatuses and methods for improving the impact performance of helmets. The disclosed apparatuses and methods allow the head to move within the helmet but dissipate forces upon the head in a plurality of directions using compressible impact-dissipating elements. The compressible impact-dissipating elements are disposed on a base between the head and an outer shell of the helmet. The compressible impact-dissipating elements are attached to the base that is configured to adapt to the interior size/shape of the helmet with which they are used. The compressible impact-dissipating elements are compressible preferably at least 50% of their “short-axis” dimension, and are also preferably capable of movement in a plurality of directions by the use of appropriate attachment elements allowing for such movement.

Disclosed are apparatuses and methods for improving the impact performance of helmets. The disclosed apparatuses and methods allow the head to move within the helmet but dissipate forces upon the head in a plurality of directions using compressible impact-dissipating elements. The compressible impact-dissipating elements are disposed on a base between the head and an outer shell of the helmet. The compressible impact-dissipating elements are attached to the base that is configured to adapt to the interior size/shape of the helmet with which they are used. The compressible impact-dissipating elements are compressible preferably at least 50% of their “short-axis” dimension, and are also preferably capable of movement in a plurality of directions by the use of appropriate attachment elements allowing for such movement.

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

A bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The bespoke sports equipment system includes methods for acquiring, storing and processing a player's unique data, namely the anatomical features of the body part against which the bespoke equipment is worn. The systems also includes methods of using the player's unique data to manufacture the bespoke protective equipment with a custom formed internal padding assembly that substantially corresponds to the player's unique data. The system and method allows for the design and manufacture of bespoke protective sports equipment that is purposely designed and manufactured to match the anatomical specifications of the player's body part.